U.S. patent application number 12/461627 was filed with the patent office on 2010-02-25 for infusion in-mould helmet.
Invention is credited to Ze-Ping Wang.
Application Number | 20100043127 12/461627 |
Document ID | / |
Family ID | 41152167 |
Filed Date | 2010-02-25 |
United States Patent
Application |
20100043127 |
Kind Code |
A1 |
Wang; Ze-Ping |
February 25, 2010 |
Infusion in-mould helmet
Abstract
A infusion in-mould helmet is disclosed. One side of a plastic
sheet that is not resistant to high temperatures is attached with a
protective tape that can withstand high temperatures, followed by
printing, plastic removal, edge cutting, and hole drilling, to form
an outer helmet. The outer helmet and a pre-formed inner helmet are
disposed together in a molding machine to render an integrally
formed sports helmet at lower pressure, lower temperature, and
shorter time.
Inventors: |
Wang; Ze-Ping; (Taipei City,
TW) |
Correspondence
Address: |
BACON & THOMAS, PLLC
625 SLATERS LANE, FOURTH FLOOR
ALEXANDRIA
VA
22314-1176
US
|
Family ID: |
41152167 |
Appl. No.: |
12/461627 |
Filed: |
August 19, 2009 |
Current U.S.
Class: |
2/425 |
Current CPC
Class: |
A42B 3/066 20130101;
A42C 2/002 20130101 |
Class at
Publication: |
2/425 |
International
Class: |
A42B 3/00 20060101
A42B003/00 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 20, 2008 |
TW |
097131670 |
Claims
1. An infusion in-mould helmet comprising an outer helmet formed by
attaching a more heat-resistant protective tape onto one surface of
a less heat-resistant plastic plate, followed by printing, plastic
removal, edge cutting, and hole drilling, wherein the outer helmet
and a pre-formed inner helmet are disposed together in a molding
machine to integrally form the in-mould helmet at lower pressure,
lower temperature, and shorter time.
2. The infusion in-mould helmet of claim 1, wherein the material of
the outer helmet is PVC.
3. The infusion in-mould helmet of claim 1, wherein the material of
the outer helmet is PET.
4. The infusion in-mould helmet of claim 1, wherein the material of
the outer helmet is PETG.
5. The infusion in-mould helmet of claim 1, wherein the material of
the inner helmet is expanded polystyrene (EPS).
6. The infusion in-mould helmet of claim 1, wherein the pressure
for infusion is not more than 0.7.+-.0.1 bar.
7. The infusion in-mould helmet of claim 1, wherein the temperature
for infusion is not more than 110.+-.2.degree. C.
8. The infusion in-mould helmet of claim 1, wherein the time for
cold fusion is not more than 168.+-.5 sec.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] The invention relates to a method of manufacturing sports
helmets and, in particular, to the method of manufacturing infusion
in-mould helmets.
[0003] 2. Related Art
[0004] The structures of sports helmets, such as bicycle helmets,
skate helmets, snow helmets, climbing helmets, and riding helmets,
are more or less the same with a harder outer shell and a softer
shock absorbing inner shell. However, higher-end helmets are
integrally formed having a thin polycarbonate outer shell with the
softer inner shell material injected into the outer shell so that
the two parts are formed together. When impact occurs, the light
harder shell and softer inner shell work together to absorb the
shock. Such types of helmet are commonly called in-mold.
[0005] The above-mentioned outer helmets are usually made of costly
polycarbonate. In view of the high cost of polycarbonate,
manufacturers are forced to consider cheaper materials instead. In
this case, PVC, PET, and PETG are potential substitutes.
Nevertheless, these cheaper substitutes cannot withstand high
temperatures during the forming process. The forming process thus
has to be done at lower temperatures. But using normal processes,
when forming at lower temperatures, the outer shell and inner shell
cannot bond together.
SUMMARY OF THE INVENTION
[0006] In view of the foregoing, an objective of the invention is
to provide in-mould helmet formed using lower temperatures but
still creating an integral bond between the two shell materials.
Plastic shell material that cannot withstand high temperatures
(such as PVC, PET, PETG and others) is first printed and then
thermoformed. And then the vents and the edges are trimmed to form
an outer helmet. The outer helmet is then pressed together with a
pre-formed inner helmet in a molding machine. They are integrally
formed into a sports helmet at lower pressure, lower temperature,
and shorter time.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The invention will become more fully understood from the
detailed description given herein below illustration only, and thus
is not limitative of the present invention, and wherein:
[0008] None.
DETAILED DESCRIPTION OF THE INVENTION
[0009] The present invention will be apparent from the following
detailed description.
[0010] The invention is implemented as follows. Outer shell
material that cannot withstand high temperatures (e.g., 90.degree.
C. or more), such PVC, PET, and PETG, is formed on thermo vacuuming
machine. Afterwards, it is made into an outer helmet after
printing, plastic removal, edge cutting, hole drilling, and so
on.
[0011] The PVC, PET, or PETG outer helmet thus formed is pressed
together with a pre-formed inner liner (normally made from expanded
polystyrene (EPS) or similar materials) in a molding machine. They
are integrally formed into a sports helmet at lower pressure
(0.5.+-.0.1 bar), lower temperature (110/2.degree. C.), and shorter
time (168.+-.5 sec).
[0012] The infusion in-mould helmet formed according to the
above-mentioned method can have the same or similar appearance,
functions, collision protection, and shock absorption as the
conventional expensive polycarbonate outer helmet.
[0013] According to the above-mentioned infusion in-mould helmet,
there is no gap between the PVC, PET, or PETG outer helmet and the
EPS inner helmet because they are integrally formed. This helps
distributing the stress during a collision, thereby protecting the
head.
[0014] The above-mentioned infusion in-mould helmet can prevent the
problem of deformation due to direct sunlight as opposed to when
the PVC, PET, or PETG outer shell is combined with the EPS inner
helmet by glue or tape.
[0015] Although the invention has been described with reference to
specific embodiments, this description is not meant to be construed
in a limiting sense. Various modifications of the disclosed
embodiments, as well as alternative embodiments, will be apparent
to persons skilled in the art. It is, therefore, contemplated that
the appended claims will cover all modifications that fall within
the true scope of the invention.
* * * * *